DTC P3004-131: Power Cable Malfunction: Procedure

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
4. Check if DTCs are output.

   Result

   DTC No.	Related Part
   P0A95	Electric vehicle fuse circuit
   P0AE7-224, P0AE6-225	SMRP control line circuit
   P0ADC-226, P0ADB-227	SMRB control line circuit
   P0A1F, P3105, P0AFA	Battery smart unit, VB sensor circuit
   P0ABF, P0AC0, P0AC1, P0AC2	IB sensor circuit
   P3004-800, 801	High-voltage power source line circuit
   P0A1A-156, 658, 151, 155, 659 P0A1B-511, 164, 163, 512, 193, 786, 788, 661 P0A78-266, 267, 523, 586, P0A94-442	VH sensor circuit

YES → GO TO DTC CHART 

NO: Go to next step 

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Select the following menu items: Powertrain / Hybrid Control / Trouble Codes.
4. Read output DTCs.
5. Read the freeze frame data for DTC P3004-131.

   Result

   Result	Proceed to
   Post-boost voltage (VH) is below 50 V and difference between HV battery voltage (PWR RESOURCE VB) and pre-boost voltage (VL) is 60 V or less.	A
   Other than above	B

A → See step   17 

B: Go to next step 

1. Check the connections of the hybrid vehicle control ECU connectors.
   Fig 1: Checking Connector Connection Condition (HV Control ECU Connector)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The connectors are connected securely and there are no contact problems.

NG → CONNECT SECURELY 

OK: Go to next step 

1. Turn the power switch off and remove the service plug grip.. Refer to PRECAUTION
2. Remove the connector cover assembly from the inverter with converter assembly. Refer to COMPONENTS .
   Fig 2: Locating Connector Cover Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Check the connection between the frame wire and the inverter with converter assembly.
   Fig 3: Identifying Frame Wire & Inverter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   OK

   The connector is connected securely and there are no contact problems.

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Check the connection between the frame wire and the HV relay assembly.
   Fig 4: Locating Frame Wire Connection

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   For the removal and installation procedures related to inspection of the frame wire connection. Refer to COMPONENTS .

   Torque: 9.0 N*m (92 kgf*cm, 81 in.*lbf) 

NG → CONNECT SECURELY 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect the frame wire from the inverter with converter assembly. Refer to COMPONENTS .
   Fig 5: Identifying Frame Wire & Inverter

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the frame wire from the HV relay assembly.
   Fig 6: Disconnecting Frame Wire From HV Relay Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Measure the resistance according to the value(s) in the table below.
   Fig 7: Identifying Red Mark On Frame Wire Frame Wire

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   w1-1 - w4-1	Below 1 Ω
   w1-2 - w5-1	Below 1 Ω

NG → REPLACE FRAME WIRE 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect connector A54 from the hybrid vehicle control ECU.
3. Disconnect the battery pack wire connector. Refer to COMPONENTS .
   Fig 8: Locating Battery Pack Wire Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Due to the time required to disconnect the HV relay assembly and hybrid vehicle converter connectors, the battery pack wire resistance check should be performed before these connectors are disconnected.

4. Measure the resistance according to the value(s) in the table below.
   Fig 9: Identifying A54 And VN1 Connectors Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   SMRB (A54-41) - CON2 (VN1-3)	Below 1 Ω
   SMRP (A54-123) - SMRP (VN1-8)	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 10: Identifying Main Battery Cable & Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check the main battery cable and the connectors for damage, poor connections or other contact problems.

   Result

   Result	Proceed to
   The connectors are connected securely and there are no contact problems.	A
   The connectors are not connected securely.	B
   HV relay assembly connector is damaged.	C
   Main battery cable is damaged.	D

   HINT: 

   The main battery cable and HV battery are supplied as one unit.

D → See step   16 

C → See step   15 

B → CONNECT SECURELY 

A: Go to next step 

1. Check that the service plug grip is not installed.
   Fig 11: Identifying Z23 & Z25 Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Measure the voltage according to the value(s) in the table below.

   Standard voltage

   Tester Connection	Specified Condition
   z23-1 - Service plug grip terminal A	114 to 190 V
   z25-1 - Service plug grip terminal B	126 to 210 V

   WARNING:

   Do not allow the probes of the electrical tester to contact each other during this inspection.

NG → See step   16 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect connector N6 from the HV relay assembly.
   Fig 12: Identifying N6 Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Before disconnecting the HV relay connector, make sure that the connector is securely engaged.

3. Measure the resistance according to the value(s) in the table below.
   Fig 13: Identifying Battery Pack Wire Connector N6

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   CON2 (VN1-3) - SMRB (N6-3)	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Disconnect connector N1 from the hybrid vehicle converter. Refer to COMPONENTS .
   Fig 14: Identifying Hybrid Vehicle Converter & N1 Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Before disconnecting the hybrid vehicle converter connector, make sure that the connector is securely engaged.

3. Measure the resistance according to the value(s) in the table below.
   Fig 15: Identifying VN1 & N1 Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   SMRP (VN1-8) - SMRP (N1-4)	Below 1 Ω

NG → REPAIR OR REPLACE HARNESS OR CONNECTOR 

OK: Go to next step 

1. Check that the service plug grip is not installed.
2. Remove the HV relay assembly from the vehicle. Refer to COMPONENTS .
3. Measure the resistance according to the value(s) in the table below.
   Fig 16: Identifying W4, Z23 & N6 Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Standard resistance

   Tester Connection	Specified Condition
   w4-1 - z23-1	Below 1 Ω (When battery voltage is applied between terminals N6-2 and N6-3)

4. Measure the resistance according to the value(s) in the table below.

   Standard resistance

   Tester Connection	Specified Condition
   SMRB (N6-3) - GND (N6-2)	18.8 to 32.1 Ω at -35 to 80°C (-31 to 176°F)

NG → See step   15 

OK: Go to next step 

HINT: 

If DTC P3004-131 is output again after performing the inspection, replace the hybrid vehicle converter. If DTC P3004-131 is not output, replace the HV relay assembly.

YES → See step   14 

NO → See step   15